Caliper pistons

[Jebus]

hello all ive started striping down my calipers, adn am unsure what which way they go in, does its hollow bit face outwards or inwards? also how do you get the bloody seals back on the thing i cant ge them back on. the bike is a dtr125.

and one more question, if i buggered the heads of the screws holding my cap on the reservoir i am screwed? (pun intended)
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2nd time around CBT: 8/9/11
125 Varadero

[mr jamez]

Hollow section of the pistons face outwards. As for the seals, you simply pop them into the grooves then slide the piston in unless the DT has some sort of fancy design I have never seen before. Remember to not mix up the fluid and dust seals.

An impact driver would be best to sort the screws on the resevoir.
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NSR 125F > BROS 400 > NC30 > BROS 400 > Trumpet S4 > '97 VFR 750

[Whosthedaddy]

[Jebus]

its geting the seals back were they are meant to thats the problem, and the heads on the scews are really chewed up
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2nd time around CBT: 8/9/11
125 Varadero

[instigator]

Take your seals out and make sure there are absolutely no bits of dirt in the grooves. Then its just a case of fiddling with them until they go in. You'll get the nack for it after you do it once or twice.

Personally, for the master cylidner thing, I'd hammer in a screw driver bit (phillips head whatever it was originally) to indent it a bit then use an impact wrench on it. Has always worked for me but might want to repalce the screws afterwards!

[mr jamez]

I don't get what you mean about the seals, sorry, any pictures or some scans of a manual? If the heads are totaly trashed the only option you have is to drill them off, then attack the remaining studs with your weapon of choice. Not sure if you can get stud removers (or similar) in that size so you may have to go for the mole grips.
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NSR 125F > BROS 400 > NC30 > BROS 400 > Trumpet S4 > '97 VFR 750

[finpos]

Take the seals out again and make sure that the grooves they sit in are sparkly clean. Lubricate the piston and seals with brake fluid and don't use too much force. You should see that the back of the piston is chamfered, it should just be a question of getting it to seat properly then one good shove.

Those screws can be a bloody nightmare. Good luck!

finpos.

[Jebus]

ill have a go at getting some pics, anyway i gotta get some rubber grease and brake fluid to put it all back together anyway, i was just trying might have to buy a drill and an impact driver then
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2nd time around CBT: 8/9/11
125 Varadero

[Jimb0b]

If the screws get rounded trying to remove them from the master cylinder cap don't worry just get a sharp pointed punch.
Place it as near the outer edge of the screwhead as possible,punch a nice indent in it straight down and once you have a good indent start hitting the indent anti clock wise using the punch on an angle.Not to much of an angle so it will slip but enough to send force on the screw in the right direction.Once it starts to move it should come straight out.
Hit the punch firmly but don't go mad,nice firm taps usually shift those smaller screws.That's how i get them out anyway.
Short sharp shock rather than whack! whack! Oh dear!.
As for the seals they should go right in as long as all the crud in the grooves is totally removed and all components are clean.

[Jebus]

Cheers for that info will have a go at that, i may still get down to the breakers and get the a new master cylinder and then have a go at this one and sort it as a spare.
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2nd time around CBT: 8/9/11
125 Varadero